Professional Documents
Culture Documents
Tanya Fletcher-Scott
CONFIDENTIAL [1]
Agenda
[2]
Getting Started-Overview
[3]
Getting Started-Overview
The Rules- Review of Standards and Guidances for Process
Validation of Devices:
Best Practice:
• ISO, EN ISO 9001 Quality management systems —Requirements
Know your
regs and
guidances
[4]
Getting Started-Overview
The Rules- Review of Standards and Guidances for Process
Validation of Devices:
[5]
Getting Started-Overview
The Rules- Review of standards and guidances for Process
Validation of Devices:
[6]
Getting Started-Overview
The Rules- Review of standards and guidances for Process
Validation of Devices:
[7]
Getting Started-Overview
The Rules- Review of standards and guidances for Process
Validation of Devices:
[8]
Getting Started-Overview
The Rules- Review of standards and guidances for Process
Validation of Devices:
[9]
Getting Started-Overview
Tools- Risk Assessments and Statistics Best
Practice:
Use your
statisticians
Statistics
(b) Sampling plans, when used, shall be written and based on a valid
statistical rationale. Each manufacturer shall establish and maintain
procedures to ensure that sampling methods are adequate for their
intended use and to ensure that when changes occur the sampling
plans are reviewed. These activities shall be documented.
[ 10 ]
Getting Started-Overview
ISO 13485
8 Measurement, analysis and improvement, 8.1 General
[ 11 ]
Getting Started-Overview
Risk Analysis
Tools- Risk Assessments and Statistics
Risk Assessments
Evaluation of overall
residual risk acceptability
[ 14 ]
Getting Started-Overview
The Team- Don’t go it alone!
[ 15 ]
Getting Started-Overview
The Team- Don’t go it alone!
The Global Harmonization Task Force- Quality Management Systems –
Process Validation Guidance suggests the following subject matter team
members:
• Quality Assurance*
Best
• Engineering* Practice:
• Manufacturing* Project Managers
are key to any
• Laboratory (Chemistry and Microbiology)* success tech
• Technical Services transfer
• Research & Development*
• Regulatory Affairs*
• Clinical Engineering
• Purchasing/Planning
• Process Excellence / Statistician*
• Project Manager*
*B+L’s typical team core members for major process validation projects
[ 16 ]
Getting Started-Overview
The Docs- Documenting the process validation activities
[ 17 ]
Getting Started-Overview
The Docs- Documenting the process validation activities
The Global Harmonization Task Force- Quality Management Systems –
Process Validation Guidance suggests the following elements in your
process validation protocols:
Elements Validation IQ OQ PQ PV
Strategy
successful validation
Identification of operators and required operator X X
Best
qualification Practice:
Validation
Strategies are a
great tool for ‘big
scope’ projects
[ 18 ]
Getting Started-Overview
The Docs- Documenting the process validation activities
The Global Harmonization Task Force- Quality Management Systems –
Process Validation Guidance suggests the following elements in your
process validation protocols:
Elements Validation IQ OQ PQ PV
Strategy
X
Length and duration of the validation
X X
Shifts, operators, equipment to be used in the
process
X X X X
Any subjective criteria used to evaluate the
product
X X
Identification of utilities for the process
equipment and quality of the utilities
X X X X X
Complete description of the process
[ 19 ]
Getting Started-Overview
The Docs- Documenting the process validation activities
The Global Harmonization Task Force- Quality Management Systems –
Process Validation Guidance suggests the following elements in your
process validation protocols:
Elements Validation IQ OQ PQ PV
Strategy
X X X X
Relevant specifications that relate to the
product, components, manufacturing
materials, etc
X X
Process parameters to be monitored, and
methods for controlling and monitoring*
X X
Product characteristics to be monitored and
method for monitoring*
X X
Any subjective criteria used to evaluate the
product
*Use of a Control Plan is a great tool and best practice. Example included in bonus material
[ 20 ]
Getting Started-Overview
The Docs- Documenting the process validation activities
The Global Harmonization Task Force- Quality Management Systems –
Process Validation Guidance suggests the following elements in your
process validation protocols:
Elements Validation IQ OQ PQ PV
Strategy
X X X X X
Definition of what constitutes non-
conformance for both measurable and
subjective criteria
X X X X
Statistical methods for data collection and
analysis
X
Consideration of maintenance and
repairs of manufacturing equipment
X
Criteria for revalidation
When it’s all done, generate the final report summarizing all
requirements, results, issues and conclusions
[ 21 ]
Agenda
[ 22 ]
Process Validation
[ 23 ]
Process Validation
[ 24 ]
Process Validation
B+L’s validation systems does not require validation strategies for smaller, less
complex validation projects whose strategy can be fully detailed within a protocol.
[ 25 ]
Process Validation
New Products
Per ISO 9001, all new products must under Design and development
which includes:
• Planning
• Design and development inputs
• Design and development outputs
• Design and development review
• Design and development verification
• Design and development validation*
• Control of design and development changes*
[ 26 ]
Process Validation
New Products
During the product transfer process, the product is being evaluated
at the manufacturing site for scale up.
New Products
Process Validation Readiness should include the following:
• Design review confirms process is capable
[ 29 ]
Process Validation
New Products
Process Validation Readiness should include the following:
• All procedures, batch records, inspection plans,
specifications, drawings are updated and approved.
[ 31 ]
Process Validation
Existing Products
Existing products are defined as validated products that have
been transferred to the manufacturing site for routine
manufacture. For validations involving any existing product,
B+L follows a global change management process.
Sec. 820.70 Production and process controls.
b-Production and process changes. Each manufacturer shall establish
and maintain procedures for changes to a specification, method,
process, or procedure. Such changes shall be verified or where
appropriate validated according to 820.75 (Process Validation), before
implementation and these activities shall be documented. Changes shall
be approved in accordance with 820.40 (Document controls).
[ 32 ]
Process Validation
Existing Products
[ 33 ]
Process Validation
Existing Products
A useful tip is to work with your Research and Development group
or Technical Services group to evaluate the capability of the
product device after proposed change.
Pros:
• Better process understanding
• Greater confidence in the process to pass when you go into live
validation.
Cons:
• May require additional equipment, line time, resources, lab support to
generate data
• Cost of material/product that may need to be scrapped
It’s a Risk decision
[ 34 ]
Process Validation
[ 35 ]
Process Validation
[ 36 ]
Process Validation
[ 37 ]
Process Validation
For the number of runs, we use 3 as a starting point. We let our risk
assessment drive the number of runs needed. Example:
[ 39 ]
Process Validation
[ 40 ]
Process Validation
Tank
Step 4
[ 42 ]
Process Validation
Tank
[ 43 ]
Case Study- Process Validation for Product XYZ
• Our product and process risk assessment identified both the bulk compounding
and sterile filling process steps as having the highest potential risk. Critical Quality
Attributes (CQAs).
• Solution is safe and effective for intended purpose (most likely impacted in bulk
compounding and sterile filling process)
• Batch is homogeneous (most likely impacted in bulk compounding)
• Raw Materials A and B must meet label claim (most likely impacted in bulk
compounding)
• We focused more effort (sampling and runs) on these high risk process steps
during scale up and process validation
[ 44 ]
Process Validation
• Based on historical data and information from our risk assessments, the heaviest
use of statistics (sampling) was focused on the bulk compounding and sterile filling
processes as we needed to demonstrate a high level of assurance at these stages.
• We used process capability data from similar products and development work to
establish standard deviations for Raw Materials A and B.
• Our sample size was based on the use of standard deviations from engineering
trials, 90% Confidence
• For batch and bottle homogeneity we demonstrated with 90%Confidence that
batch and bottle sample sets were homogeneous.*
[ 45 ]
Process Validation
When are you done?
[ 46 ]
Process Validation
When are you done?
According to GHTF - Quality Management Systems Process
Validation Guidance, you should maintain a state of
validation:
[ 47 ]
Process Validation
When are you done?
Most companies including B+L are using the product quality review
process to confirm medical device products are maintained in a state of
control. Key attributes include:
• Complaints
• Non-conformances
• Stability
[ 49 ]
Enterprise wide Roll Out of Process Validation
o Train personnel
[ 50 ]
Enterprise wide Roll Out of Process Validation
[ 51 ]
Enterprise wide Roll Out of Process Validation
Pros:
• Provides clear instruction for ‘how things are done’.
• Offers consistent approach to validation to train to and follow regardless of site
location, manufacturing platform, products manufactured
• Presents to regulators the company’s position on process validation
• Capitalize on best practices at each site. Best
• Ensures alignment to guidances, standards and industry best Practice:
practices In addition to policies
and procedures,
templates provide
consistency
[ 52 ]
Enterprise wide Roll Out of Process Validation
Cons:
• Difficult to gain consensus with multiple sites who have always ‘done it
their way’.
• Procedures and templates may not be flexible to meet needs of different
products, manufacturing platforms
• Learning curve and time to implement
[ 53 ]
Enterprise wide Roll Out of Process Validation
5.6.2 Review input- The input to management review shall include information
on:
a) results of audits, (Internal and External Audits)
b) customer feedback, (Complaints)
c) process performance and product conformity, (NonConformance Management)
d) status of preventive and corrective actions, (NonConformance Management)
e) follow-up actions from previous management reviews,
f) changes that could affect the quality management system, and (Change Mgmt)
g) recommendations for improvement. (Continuous Improvement)
[ 54 ]
Enterprise wide Roll Out of Process Validation
5.6.3 Review output- The output from the management review shall include any
decisions and actions related to:
a) improvement of the effectiveness of the quality management system and its
processes,
b) improvement of product related to customer requirements, and
c) resource needs.
[ 55 ]
Enterprise wide Roll Out of Process Validation
[ 56 ]
Agenda
[ 57 ]
Interactive Exercise
[ 58 ]
Interactive Exercise
• Product ABC is currently filled in an oval and opaque HDPE. New
bottle is round, transparent (without colorant) HDPE
• Bottle will be filled in Fill Room C. Fill Room C only has change
parts for oval bottles.
[ 59 ]
Interactive Exercise
Each team, take 5-10 minutes to develop a validation strategy.
Demonstrate the use of the following:
• Success criteria
• Team Members
• Training
• Proposed statistics
[ 61 ]